Abstract: A vehicle body positioning and locking devices for use in assembling a vehicle body positioned on a movable vehicle support positioned at a vehicle build station. The locking device includes a remote vehicle locking device for selectively securing and locking a vehicle body to a support pallet. The support pallet is accurately and precisely positioned at a build station through alignment and inserting engagement of locating pads in at least one four-way and at least one two way receiver mounted to a build station foundation. A compliant body clamp design is included to provide a desired clamping force between the pallet and a vehicle body across a range of motion of the body clamp to accommodate vehicle build variances.

Abstract: A thermal metal spraying apparatus for use with a thermal metal spraying torch for applying a metal coating to a workpiece through a torch spraying nozzle having a spraying orifice. The thermal metal spraying apparatus provides a substantially tubular shroud having a first end and a second end adaptable to concentrically receive the torch spraying nozzle. The shroud has an opening at the second end, wherein the opening is selectably alignable with the spraying orifice. A drive mechanism is connected to the shroud and is operable to translate the shroud between a first position, wherein the opening at the second end is not aligned with the spraying orifice, thereby preventing the spraying of the metal coating on the workpiece, and a second position, wherein the opening at the second end is aligned with the spraying orifice permitting the spraying of the metal coating toward the workpiece.

Abstract: A multiple natural frequency coupling apparatus for connecting a rotatable driving member to a rotatable driven member of a drive line. The coupling apparatus of the present invention provides a substantially cylindrical housing having a longitudinal axis with a substantially cylindrical outer shaft coaxially aligned with and connected to the housing. A substantially cylindrical inner shaft is coaxially aligned with the outer shaft and the housing. A substantially cylindrical chuck housing is coaxially aligned with the housing, the outer shaft, and the inner shaft wherein the fluid chuck housing is connected to the inner shaft.

Abstract: A flexible leak test apparatus and method for leak testing a variety of workpieces having various multiple configurations with at least one internal cavity and at least one aperture leading therefrom. The flexible leak test apparatus and method provide a plurality of leak test fixtures adaptable to receive the workpieces. Each leak test fixture has a bottom portion and a top portion that engage one another when the workpieces are loaded in the bottom portion of the leak test fixture. The leak test fixtures are shuttled in and out of the workstation, and a manipulator loads and unloads the workpieces into and out of the bottom portion of the leak test fixtures. The leak test fixtures seal the apertures in the workpieces so that the workpieces can be leak tested by pressurizing the internal cavity of the workpiece.

Abstract: A combination component handling and connecting device connectable to a multi-axis robot for use in moving and connecting components and subassemblies includes a housing and an actuator fixedly connected to the housing. The actuator includes an actuating link movable from a first position to a second position. Connected to the actuating link is an end effector for concurrent movement with the actuating link. The component handling and connecting device includes a clamp having a first jaw and a second jaw. The second jaw is connected to the actuating link for selectively moving the second jaw toward the first jaw operative to engage a component.

Abstract: Disclosed herein are embodiments and methods of a visual guidance and recognition system requiring no calibration. One embodiment of the system comprises a servo actuated manipulator configured to perform a function, a camera mounted on the face plate of the manipulator, and a recognition controller configured to acquire a two dimensional image of the work piece. The manipulator controller is configured to receive and store the face plate position at a distance “A” between the reference work piece and the manipulator along an axis of the reference work piece when the reference work piece is in the camera's region of interest. The recognition controller is configured to learn the work piece from the image and the distance “A”. During operation, a work piece is recognized with the system, and the manipulator is accurately positioned with respect to the work piece so that the manipulator can accurately perform its function.

Abstract: A system and method for sequencing component part delivery for use in assembling vehicle bodies arranged in a substantially random assembly sequence. The system and method includes a plurality of kit carts that are loaded or stocked with vehicle specific parts in a sequence or staging area of an assembly facility. The vehicle specific stocked carts are arranged and positioned to a coordinated vehicle to assemble the vehicle using the kit carts that move along in sequence with the vehicle as the vehicle is assembled along an assembly line. As the carts are depleted of parts, the carts are returned for restocking and assigned to a subsequent vehicle.

Abstract: A vehicle body positioning and locking devices for use in assembling a vehicle body positioned on a movable vehicle support positioned at a vehicle build station. The locking device includes a remote vehicle locking device for selectively securing and locking a vehicle body to a support pallet. The support pallet is accurately and precisely positioned at a build station through alignment and inserting engagement of locating pads in at least one four-way and at least one two way receiver mounted to a build station foundation. A compliant body clamp design is included to provide a desired clamping force between the pallet and a vehicle body across a range of motion of the body clamp to accommodate vehicle build variances.

Abstract: A method of sequentially performing a plurality of jointing operations includes positioning an automated device to form a mechanical joint into a workpiece and forming a mechanical joint into the workpiece. Once the mechanical joint is formed, the workpiece is scanned to generate data indicating the surface geometry of the workpiece at a location including the mechanical joint. One or more geometric features of the surface geometry are identified, and if the identified geometric features are within respective predetermined specification thresholds, the automated device is repositioned to form a subsequent mechanical joint into the workpiece.

Abstract: Disclosed is a method for controlling a plurality of machines. The method includes identifying a first prerequisite operating condition for a first machine in the plurality of machines, the first machine having at least one control unit and configured to perform at least a first operation, obtaining at least one current operating condition corresponding to a second machine in the plurality of machines and if the at least one current operating condition meets the first prerequisite operating condition, performing the first operation.

Abstract: Methods for welding motor vehicle body component subassemblies at a weld stations are disclosed. First and second pallets may be arranged for reciprocal movement between a load/unload station and the weld station and the pallets are alternately moved from a load/unload station to the weld station while the other pallet is moved from the weld station to a load/unload station. Each pallet may have a plurality of substations for receipt of component subassemblies and, while each pallet is at the load/unload station, the component subassembly at each substation is moved to the next successive substation and a further component is added to the moved component.

Abstract: A modular manufacturing facility and method of construction includes a plurality of service and equipment modules which are readily sized and oriented to be packaged, shipped to a desired location, assembled and connected to local resources to form a fully operational assembly or build facility substantially or wholly independent of any resident building structure at the selected site.

Abstract: A method and apparatus for managing the delivery of component parts and tooling to a robotic welding assembly positioned on a motor vehicle body assembly line. Automatic guided vehicles deliver component parts from a source of parts to a parts staging area on the robotic welding assembly including a substage awaiting area, a substage in-use area and a substage empty area, and further automatic guided vehicles deliver tooling from a tooling management area to the robotic welding assembly whereafter the tooling, upon model changeover, is moved to a tooling use area proximate the assembly line whereafter, upon further model changeover, the tooling is removed from the tooling use area and loaded onto an automatic guided vehicle for return to the tooling management area.

Abstract: An apparatus for positioning a workpiece carrier with respect to a workstation can include a workpiece carrier movable relative to the workstation and having an encoder strip, at least one encoder reader located at the workstation for generating a signal in response to interaction with at least one encoder strip, and a drive engaging the workpiece carrier for moving the carrier relative to the workstation, the drive responsive to the signal from the encoder reader. A closed loop feedback control system can be provided for receiving the signal from the encoder reader, and for generating an output signal in response to the signal from the encoder reader in accordance with a program stored in memory.

Abstract: An apparatus for welding motor vehicle body component subassemblies at a weld station. First and second pallets are arranged for reciprocal movement between a load/unload station and the weld station and the pallets are alternately moved from a load/unload station to the weld station while the other pallet is moved from the weld station to a load/unload station. Each pallet has a plurality of substations for receipt of component subassemblies and, while each pallet is at the load/unload station, the component subassembly at each substation is moved to the next successive substation and a further component is added to the moved component.

Abstract: A vehicle body assembly and sequencing system includes the advantages of a batch vehicle body build sequence with the advantages of a random sequence of vehicle body styles transferred to a painting area. The build system includes using automated guided vehicles which transfer and store assembled, un-painted vehicle bodies in a storage area and sequentially transfers selected bodies from the storage area to the painting area achieving a random or variable supply of different vehicle bodies to be painted a certain color.

Abstract: A palletized framing system for a motor vehicle body assembly system in which the pallet with a body structure positioned thereon is positioned at the framing station on balls to establish the vertical Z dimension with the pallet free to float on the balls in longitudinal X and lateral Y dimensions, whereafter positioners carried by one of the gates of the framing station engage and lock onto the pallet to precisely position the pallet and the body structure at the framing station at X and Y dimensions corresponding to the precisely attainable X and Y positioning of the gate.

Abstract: A method and apparatus for assembling a complex product in a parallel process system wherein a collection of components are provided for assembling the complex product. The present invention involves transferring the collection of components to one of a plurality of similar computerized assembly cells through the use of a transport system. The collection of components is automatically assembled into the complex product through the use of the computerized assembly cells. The complex product is then transferred from one of the assembly cells to a computerized test cell, where the complex product is tested to ensure for the proper dimensioning and functioning of the complex product. The complex product is then transferred from the test cell via the transport system to either a part reject area or conveyor, if the product is defective, or to an automatic dunnage load or part return system, if the product is not defective.

Abstract: An automated guided cart (AGC) that is configured to travel along a cart path according to generally non-precision movements is implemented to support a build process requiring precise positioning of vehicle build devices. In an example of a method of use, a vehicle build device for the build process is engaged with the AGC. When the AGC travels proximate a build operation area, the AGC can be secured in a dimensionally fixed position, with the result that both the AGC and a vehicle build device engaged with the AGC are located in precise positions. Based on the precise location of the vehicle build device, the vehicle build device can be interfaced with robots or other automated equipment according to preprogrammed and/or precise movements to carry out a build process.

Abstract: A method and apparatus for managing the delivery of component parts and tooling to a robotic welding assembly positioned on a motor vehicle body assembly line. Automatic guided vehicles deliver component parts from a source of parts to a parts staging area on the robotic welding assembly including a substage awaiting area, a substage in-use area and a substage empty area, and further automatic guided vehicles deliver tooling from a tooling management area to the robotic welding assembly whereafter the tooling, upon model changeover, is moved to a tooling use area proximate the assembly line whereafter, upon further model changeover, the tooling is removed from the tooling use area and loaded onto an automatic guided vehicle for return to the tooling management area.